Apparatus for Automated Maintenance of Aircraft Structural Elements

ABSTRACT

Automated apparatus for performing maintenance functions on airfoil-shaped bodies having short chord lengths, the apparatus being movable in a spanwise direction along the airfoil-shaped body. In accordance with various embodiments, the apparatus comprises a blade crawler capable of supporting any one of a plurality of end effectors for performing a set of maintenance functions on an airfoil-shaped body, such as a blade component. Included in these functions are multiple options for nondestructive inspection, drilling, grinding, fastening, appliqué application, scarfing, ply mapping, depainting, cleaning, and painting devices that are attached as the end effector for the blade crawler. As a whole, the blade crawler reduces maintenance time, labor hours and human errors when robotic maintenance functions are performed on blade components.

RELATED PATENT APPLICATIONS

This application is a divisional of and claims priority from U.S. patentapplication Ser. No. 15/222,028 filed on Jul. 28, 2016, which in turn isa divisional of and claims priority from U.S. patent application Ser.No. 13/663,709 filed on Oct. 30, 2012 and issued as U.S. Pat. No.9,643,313 on May 9, 2017, which in turn is a continuation-in-part of andclaims priority from U.S. patent application Ser. No. 12/657,424 filedon Jan. 19, 2010 and issued as U.S. Pat. No. 8,347,746 on Jan. 8, 2013.

BACKGROUND

The present disclosure relates generally to the field of automatedmaintenance (including nondestructive inspection) of aircraft structuralelements such as airfoil-shaped bodies, and more particularly to anautomated end effector-carrying apparatus that is coupled to and travelsalong an airfoil-shaped body having a relatively short chord length,such as a rotorcraft blade, an aircraft propeller blade, a winglet, aprojectile fin, an aircraft horizontal stabilizer, etc., whileperforming a maintenance function.

As used herein, the term “maintenance” includes, but is not limited to,operations such as nondestructive inspection, drilling, scarfing,grinding (e.g., to remove bonded or bolted components), fastening,appliqué application, ply mapping, depainting, cleaning and painting.

In order to provide maintenance for airfoil-shaped bodies such as bladecomponents, it is known to manually remove the blade components from theaircraft and then manually perform the maintenance functions. Removal ofblade components from an aircraft is cost intensive. With helicopterblades, for example, the time spent removing, transporting,re-attaching, balancing and trimming the blades can be significant. Somehelicopters require that the blades be removed and inspected every 50-75flight hours, resulting in a dramatically reduced mission capability ofthe aircraft.

Furthermore, performing maintenance functions manually requires skilledtechnicians. These technicians are in short supply; therefore the laborcost to manually perform maintenance functions is significant.

Because manual maintenance is complex and repetitive, the likelihood ofhuman error is high. When a repetitive maintenance operation is botchedby a human, the flawed blade component could be reattached to theaircraft with a dangerous flaw still imbedded in the component. Anaircraft accident could result from the blade component failing at thepoint of the flaw that could have been avoided with the use of a robot.

It would be desirable to have an automated apparatus for performingmaintenance functions on airfoil-shaped bodies having short chordlengths, without the necessity of removing the airfoil-shaped body fromthe aircraft.

SUMMARY

The subject matter disclosed herein is an automated apparatus forperforming maintenance functions on airfoil-shaped bodies having shortchord lengths, without the necessity of removing the airfoil-shaped bodyfrom the aircraft. In accordance with various embodiments, the apparatuscomprises a platform, an end effector selected from a group ofinterchangeable end effectors and carried by the platform, means formounting the end effector-carrying platform on an airfoil-shaped body,means for moving the end effector-carrying platform in a spanwisedirection along the airfoil-shaped body, and means for moving the endeffector in a chordwise direction relative to the airfoil-shaped bodywhen the platform is stationary.

In accordance with one embodiment, the apparatus comprises a bladecrawler capable of supporting any one of a plurality of end effectorsfor performing a set of maintenance functions on an airfoil-shaped bodysuch as a blade component. Included in these maintenance functions aremultiple options for nondestructive inspection, drilling, grinding,fastening, appliqué application, scarfing, ply mapping, depainting,cleaning, and painting devices that are attached as the end effector forthe blade crawler. The blade crawler is movable in a spanwise directionand comprises a traveling element (e.g., a slider) that is linearlytranslatable in a chordwise direction when the spanwise-movable bladecrawler is stationary. A selected one of a plurality of end effectorscan be attached to the traveling element. In accordance with eachmaintenance operation, the selected end effector can be moved in achordwise direction when the blade crawler is not moving in the spanwisedirection. There are a number of types of blade components on aircraftthat will benefit from maintenance automation, including helicopterblades, propeller blades, flaps, ailerons, trim tabs, slats, stabilatorsand stabilizers. As a whole, the blade crawler reduces maintenance time,labor hours and human errors when robotic maintenance functions areperformed on blade components.

To facilitate the mounting and removal of the automated blade crawlerdisclosed herein and prevent damage to the rotorcraft blade due to theweight of the crawler, an adjustable blade tip stabilizing apparatus isprovided for supporting the tip of a rotorcraft blade during inspectionor maintenance. This feature enables the crawler to function on smalleror less stiff rotorcraft blades without overloading them. The blade tipstabilizing apparatus further comprises a cable payout subsystem formanaging the cables which connect the crawler to the operations center.

The disclosed blade crawler and blade stabilizer will enable on-aircraftmaintenance operations. This means that the blade component will notneed to be removed from the aircraft, and the functions of removing,transporting, re-attaching, balancing and trimming need not beperformed, resulting in a dramatically increased mission capability ofthe aircraft. In addition, performing maintenance functions roboticallywith a blade crawler will reduce the workload on the limited number ofskilled technicians, thus reducing the labor cost to perform maintenancefunctions. Also, human error will be dramatically reduced with the bladecrawler performing the complex repetitive maintenance processes on bladecomponents. Fewer aircraft accident will result from the blade componentfailing because fewer flaws will be passed to the aircraft because arobot was employed.

One aspect of the subject matter disclosed in detail hereinafter is anautomated apparatus for moving an end effector over a surface of anairfoil-shaped body having leading and trailing edges, comprising: achassis comprising leading and trailing edge subassemblies which aremovable relative to each other to change a state of the chassis from afirst state to a second state; a plurality of rolling elements rotatablymounted to the leading and trailing edge subassemblies, the plurality ofrolling elements being situated so that the airfoil-shaped body cannotbe engaged with a gripping force when the chassis is in the first stateand being situated so that the airfoil-shaped body can be engaged with agripping force when the chassis is in the second state; a first actuatorcoupled to rotate one of the plurality of rolling elements whenactivated; a support assembly coupled to and displaceable along thechassis; a second actuator coupled to displace the support assembly whenactivated; an end effector coupled to and carried by support assembly;and a third actuator coupled to actuate operation of the end effectorwhen activated. Optionally, the apparatus further comprises a fourthactuator coupled to change the state of the chassis from the first stateto the second state when activated. In accordance with a further option,a fifth actuator could be arranged to raise and lower an end effectorthat is displaceable along a vertical arm. In accordance with oneembodiment, a control computer located at an operations center isprogrammed to activate the actuators via an electrical cable. The endeffector may comprise one of the following: a nondestructive inspectionsensor, a drill motor or other rotary tool (such as a scarfer orgrinder), a ply mapper, a squirter, a sprayer, a wiper, a continuouscleaning device, a roller that carries liquid and a suction or vacuumdevice for liquid runoff capture.

Another aspect is an automated apparatus for moving an end effector overa surface of an airfoil-shaped body having leading and trailing edges,comprising: a first support assembly comprising a forward body part, arearward body part, and an intercostal element that interconnects theforward and rearward body parts, at least one of the forward andrearward body parts being displaceable along an axis of the intercostalelement to facilitate adjustment of the distance separating the forwardand rearward body parts; a first drive motor carried by the forward bodypart; a drive mechanism coupled to and depending from an output shaft ofthe drive motor and arranged to contact the airfoil-shaped body; arolling element supported by the rearward body part and arranged tocontact the airfoil-shaped body; a biasing mechanism coupled to theintercostal element and one of the forward and rearward body parts forexerting a force that urges the drive mechanism and the rolling elementto grip the airfoil-shaped body; a guide element supported by the firstsupport assembly; a second support assembly which is mounted on anddisplaceable along the guide element; and an end effector coupled to andcarried by the second support assembly, wherein the first supportassembly is displaceable in a spanwise direction along theairfoil-shaped body when the drive mechanism is driven by the drivemotor, and the end effector is displaceable in a chordwise directionindependent of spanwise displacement of the first support assembly.

A further aspect is an apparatus comprising a ladder, a frame memberattached to the ladder, a height adjustment mechanism comprising a lowerpart attached to the ladder and an upper part which is coupled to thelower part of the height adjustment mechanism, a pair of cable pay-outrollers rotatably coupled to the frame member, and a grip attached tothe upper part of the height adjustment mechanism, wherein the grip isconfigured to engage and stabilize a tip of a rotorcraft blade, and theheight of the upper part of the height adjustment mechanism isadjustable by movement relative to the lower part.

Yet another aspect is a system comprising: an airfoil-shaped body havingleading and trailing edges which extend from a root to a tip; a tipsupport assembly comprising a frame, a height adjustment mechanismcomprising a lower part attached to the frame and an upper part which iscoupled to the lower part of the height adjustment mechanism, first andsecond cable pay-out rollers rotatably coupled to the frame, and a gripattached to the upper part of the height adjustment mechanism andcoupled to the tip of the airfoil-shaped body, wherein the height of theupper part of the height adjustment mechanism is adjustable by movementrelative to the lower part; an automated blade crawler mounted to theairfoil-shaped body, the automated blade crawler comprising an endeffector, first means for moving the blade crawler in a spanwisedirection along the airfoil-shaped body, and second means for moving theend effector in a chordwise direction; and a cable having one endconnected to the automated blade crawler and having another portiondisposed between the first and second cable pay-out rollers.

Other aspects of the invention are disclosed and claimed below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a blade crawler driven by a drive track134, as disclosed in U.S. patent application Ser. No. 12/657,424, thecrawler being mounted on an airfoil structure having a short chordlength and carrying a nondestructive inspection sensor.

FIG. 2 is an isometric view of the apparatus depicted in FIG. 1, mountedon an airfoil structure having a relatively shorter chord length.

FIG. 3 is an isometric view of a variation of the apparatus depicted inFIG. 1 in which the drive track 134 has been replaced by a drive roller122 and a follower wheel 124.

FIG. 4 is an isometric view of a blade crawler in accordance with analternative embodiment (also disclosed in U.S. Patent Application Ser.No. 12/657,424) that is capable of performing nondestructive inspectionon the top surface, the leading edge and the bottom surface of theairfoil structure in sequence.

FIG. 5 is a diagram showing some components of the blade crawlerdepicted in FIG. 4 and showing the airfoil in section, the section beingtaken along a section line A--A indicated in FIG. 4. For the purpose ofsimplicity, this sectional view through the airfoil indicates that theairfoil in the sectional plane is solid material. However, it should beunderstood that most airfoils have a hollow internal structure, e.g., ahoneycomb-like structure.

FIG. 6 is a diagram showing some components of a blade crawler inaccordance with a further embodiment (disclosed in U.S. patentapplication Ser. No. 12/657,424) that is capable of performingnondestructive inspection on the top and bottom surfaces and along theleading edge of the airfoil concurrently. Again, for the purpose ofsimplicity, a solid airfoil has been shown in section, although mostairfoils have a hollow internal structure.

FIG. 7 is an isometric view of the leading edge scanning assembly 180shown in FIG. 3. This same leading edge scanning assembly can beincorporated in the embodiment shown in FIG. 6.

FIG. 8 is a diagram showing an isometric view of a rotary scarfersupported on an adjustable chassis of a blade crawler, the adjustablechassis comprising a telescoping sleeve.

FIG. 9 is a block diagram showing communications between a controlcomputer and various components of a blade crawler in accordance withone embodiment.

FIG. 10 is a diagram showing a grooved drive roller and a pair ofparallel-axis alignment wheels in contact with a leading edge of anairfoil-shaped body in accordance with one embodiment.

FIG. 11 is a diagram showing a flat drive roller and a pair of off-axisalignment wheels in contact with a leading edge of an airfoil-shapedbody in accordance with another embodiment.

FIG. 12 is a diagram showing a flat drive roller and a single off-axisalignment wheel in contact with a leading edge of an airfoil-shaped bodyin accordance with a further embodiment.

FIG. 13 is a diagram showing a pair of off-axis alignment wheels incontact with a leading edge of an airfoil-shaped body, the alignmentwheels being rotatably mounted on a flexible axle in accordance withanother embodiment.

FIG. 14 is a diagram showing an isometric view of portions of a bladecrawler in accordance with an alternative embodiment in which thecrawler carries a rotary scarfer and the adjustable chassis comprises achordwise grip mechanism having a pincers configuration.

FIG. 15 is a diagram showing an isometric view of portions of a bladecrawler in accordance with another embodiment in which the crawlercarries a rotary scarfer and the adjustable chassis comprises achordwise grip mechanism having a scissors configuration.

FIG. 16 is a diagram showing an isometric view of portions of a bladecrawler in accordance with a further embodiment in which the crawlercarries a rotary scarfer and the adjustable chassis comprises achordwise grip mechanism having a clam-shell configuration.

FIG. 17 is a diagram showing an isometric view of portions of a bladecrawler in accordance with a variation of the embodiment depicted inFIG. 16. In this variation, the adjustable chassis comprises a chordwisegrip mechanism having a clam-shell front edge configuration.

FIG. 18 is a diagram showing an isometric view of portions of a bladecrawler in accordance with yet another embodiment in which the crawlercarries a rotary scarfer and the adjustable chassis comprises achordwise grip mechanism having a press configuration.

FIG. 19 is a diagram showing an isometric view (backside) of portions ofa blade crawler in accordance with a further embodiment in which thechassis of the crawler carries a pressure foot brake mechanism.

FIG. 20 is a diagram showing an isometric view (backside) of portions ofa blade crawler in accordance with a further embodiment in which the endeffector carries a pressure foot brake mechanism.

FIG. 21A is a diagram showing a side view of a rotorcraft blade havingan automated blade crawler mounted thereon, the blade tip beingsupported by a stabilizer in accordance with one embodiment. A frame ofa cable payout roll assembly is not shown in FIG. 21A, but is shown inFIG. 21B.

FIG. 21B is a diagram showing a view of the rotorcraft blade stabilizerdepicted in FIG. 21A.

Reference will hereinafter be made to the drawings in which similarelements in different drawings bear the same reference numerals.

DETAILED DESCRIPTION

U.S. patent application Ser. No. 12/657,424, in its broadest sense,disclosed an autonomous, self-propelled, expandable and adjustableapparatus for inspecting in-service airfoil-shaped structures such asrotorcraft blades, aircraft propellers, smaller winglets, and narrowtail sections for structural damage by crawling along the length of theairfoil-shaped structure using the structure itself as the track, andemploying scanning sensor mechanisms such as ultrasonic pulse echo, eddycurrent arrays, resonance arrays, and bond tester or laser probes, toacquire data representing the structural conditions found as theinspection apparatus moves across the surface. Multiplexedpulser/receiver cards, and a controller within a computer with imagingsoftware, can be cabled to the expandable crawler portion of the systemto collect, display, and store NDI data.

As seen in FIG. 1 (taken from U.S. patent application Ser. No.12/657,424) an inspection apparatus 100 (hereinafter referred to as a“crawler”) comprises a forward body part 102, a rearward body part 104,and an intercostal element 150 that interconnects the forward andrearward body parts to form a chassis. One of the forward and rearwardbody parts is displaceable along an axis of the intercostal element tofacilitate adjustment of the distance separating the forward andrearward body parts, while the other body part is fixed relative to theintercostal element. For example, the intercostal element may comprise acircular cylindrical tube or rod having one end fixed to the forwardbody part 102, while a portion extending from the other end has therearward body part 104 slidably mounted thereon in the manner of atelescoping sleeve, allowing the distance between the forward andrearward body parts to be adjusted to adapt to airfoil-shaped bodieshaving different chord lengths.

The forward body part 102 is positioned near a forward (i.e., leading)edge of the airfoil-shaped body 170 that is to be inspected, and therearward body part 104 is positioned near an opposing (i.e., trailing)edge of the structure to be inspected. Inspection of the airfoil-shapedbody 170 is carried out, in part, by a face-sheet scanner 112 pivotallymounted on one end of an arm 114, the other end of the arm 114 in turnbeing pivotably mounted to a slider 116 coupled to and slidable on aguide rod 118. (Alternatively, a guide rail or other guide element couldbe used in place of a guide rod.) The face-sheet scanner 112 maycomprise any one of a variety of NDI sensors to perform inspection ofthe airfoil-shaped body 170.

In accordance with one embodiment, scanner 112 follows the curvedsurface of the airfoil-shaped body 170 when arm 114 exerts a normalforce on the pivotably supported scanner 112. The normal force keeps thescanner in intimate contact with the airfoil surface, thus enabling theNDI functionality of the scanner. In cases where the scanner comprisesan array of ultrasonic transducers, acoustic couplant may be suppliedfrom the operations center to the interface of the scanner and airfoil,for example, via a hose. The normal force exerted by the arm 114 can begenerated by any conventional means, including the coupling of a spring,solenoid, pneumatic actuator or radial motion transducer (not shown inthe drawings) between arm 114 and slider 116.

The forward body part 102 has a first rod 131 depending therefrom onwhich is mounted a control motor 132. A drive wheel (not shown) isoperatively connected to and supported from the control motor 132, thelatter causing a drive track 134 to circulate the drive wheel and asecond wheel (also not shown) while drive track 134 stays in frictionalcontact with the leading edge (LE in FIG. 1) of the airfoil-shaped body170. Rotation of rod 131 causes the crawler 100 to travel in a spanwisedirection provided that the drive track 134 does not slip relative tothe leading edge.

Still referring to the embodiment depicted in FIG. 1, a second rod 142depends from the rearward body part and carries a follower encoder wheel144 on the free end thereof. The spanwise position of crawler 100 ismeasured by a rotary encoder (incorporated in the rearward body part104), which encodes rotation of encoder wheel 144. The encoder wheel 144rides on the airfoil surface as the crawler travels in the spanwisedirection. The rotary encoder sends an encoder pulse to the operationscontrol center (e.g., via an encoder cable or a wireless connection)after each incremental movement of crawler 100 in the spanwisedirection, which encoder pulses are used by a control computer (notshown in FIG. 1, but see item 50 in FIG. 9, to be described in detaillater) and by ultrasonic pulser/receiver devices (not shown in thedrawings) to determine the spanwise coordinate of each scan plane in awell-known manner.

The drive track 134 and the encoder wheel 144 are held against, and infrictional engagement with, the leading and trailing edges,respectively, of the airfoil-shaped body 170 to be inspected. This isaccomplished by application of a tensile force imparted to the forwardand rearward body parts 102, 104 (to be discussed below). The front andrearward body parts in turn (in response to the tensile force appliedbetween the front and rearward body parts) apply a compressive force onthe blade component (via the drive track 134 and encoder wheel 144) thatholds the crawler on the blade component. Preferably, drive track 134 ismade of a material that frictionally engages the leading edge of thestructural part being inspected so as to impart a driving force thatmoves the crawler 100 spanwise along the airfoil-shaped body 170.Additionally, the encoder wheel 144 tracks the spanwise position of thecrawler 100 as it translates along the airfoil-shaped body 170.

The rearward body part 104 carries encoder wheel 144, which dependsfrom, and is attached to, the rearward body part on a telescoping rod142 that allows the vertical position of the encoder wheel to beadjusted to fit the trailing edge of the airfoil-shaped body 170. Thedrive track 134 and encoder wheel 144, in conjunction, exert a grippingforce on the airfoil-shaped body 170 that holds the crawler 100 thereon.The gripping force can be generated by a spring (not shown) whichextends between the intercostal element 150 and the rearward body part104. In accordance with one embodiment, the spring has opposing endsattached to (for applying a tensile force between) the rearward bodypart 104 and one of a plurality of attachment points spaced along thelength of the intercostal element 150.

The forward body part 102 also carries a leading edge scanner assembly180 that supports a leading edge sensor array 181 (see FIGS. 6 and 7 andthe accompanying discussion for a detailed description of leading edgescanner assembly 180). Inside the leading edge scanner assembly 180 (seeFIG. 7), sensor array 181 is conformably supported by a leading edgescanner frame 182 which is horizontally adjustable toward and away fromthe leading edge of the airfoil-shaped body 170 on adjustment rod 184,and vertically adjustable relative to the leading edge of theairfoil-shaped body 170 on a second adjustment rod 186.

Various types of sensors may be utilized to perform non-destructivetesting. One or more sensors may move over the portion of the structureto be examined, and receive data regarding the structure. For example, apulse-echo, thru-transmission, or shear wave sensor may be utilized toobtain ultrasonic data, such as thickness gauging, detection of laminardefects and porosity, and/or detection of cracks in the structure.Resonance, pitch/catch or mechanical impedance sensors may be utilizedto provide indications of voids or porosity, such as in adhesivebondlines of the structure. In addition, single and dual current eddycurrent sensors impart and detect eddy currents within a structure so asto identify cracks and/or corrosion, particularly in metallic or otherconductive structures. The data acquired by the sensors is typicallyprocessed by a processing element, and the processed data may bepresented to a user via a display in a conventional manner.

Referring again to FIG. 1, to translate the face sheet scanner 112chordwise across the airfoil-shaped body 170, it is contemplated that amotor will be encased within the slider 116 to interact with the guiderod 118 via gears or friction wheels. Alternatively, the chordwisemotion may be achieved by positioning the motor on the forward body part102 and translating the slider 116 via a cable, drive belt, chain, orscrew-drive in a well-known manner.

FIG. 2 shows the crawler 100 of FIG. 1 mounted on an airfoil-shaped body170 having a chord length less than the chord length of theairfoil-shaped body 170 shown in FIG. 1. As described previously, atensile force can be applied by an internal tension spring that extendsbetween an attachment point (not shown) on the intercostal element 150and an attachment point (not shown) on the movable rearward body part104. Multiple attachment points can be provided on the intercostalelement 150 so that a spring tension within desired operational limitscan be maintained during respective inspections of blades havingdifferent chord lengths. When one end of the tension spring is unlookedfrom a current attachment point, the rearward body part 104 can betranslated along the intercostal element 150 in either direction andthen the tension spring can be hooked onto a new attachment point,selected to produce a desired spring tension. In this manner, thecrawler 100 can be expanded or retracted to accommodate structuralelements having a range of chord lengths, as illustrated in FIGS. 1 and2.

FIG. 3 shows a second embodiment of crawler 100 that includes the sameelements depicted in FIG. 1, except that the drive track shown in FIG. 1has been replaced by a drive roller 122 operatively coupled to thecontrol motor 132 (carried by forward body part 102) and a secondaryfollower wheel 124 displaced spanwise from the drive wheel (also carriedby forward body part 102).

FIGS. 4 and 5 depict a further embodiment in which the structuralelement can be scanned around its entire periphery using a crawler 100having a continuous guide rod 166 supported by upper and lower chasseshaving structures which mirror each other. The upper chassis comprisesforward body part 102, intercostal element 150 [Not on figure] andrearward body part 104 positioned above the airfoil-shaped body 170,while the lower chassis comprises a second forward body part (hidden inFIG. 4), intercostal element 150′ and rearward body part 104′ positionedbelow the airfoil-shaped body 170. The upper and lower chassis, inconjunction with the drive track and encoder wheel (and their axles),form a crawler capable of travel in a spanwise direction when mounted onthe airfoil-shaped body 170.

The continuous guide rod 166 can be integrally formed with a pair ofmounting plates 172 (only the upper mounting plate is visible in FIG. 4)that are fastened to the respective forward body parts of the upper andlower chasses. As best seen in FIG. 5, the continuous guide rod 166supports the slider 116 to which a NDI scanner element 112′ is attached.The continuous guide rod 166 extends, with a gradual curvature, from therearward body part to the forward body part of the upper chassis (notshown in FIG. 5), and then, with a reduced radius, extends from theforward body part of the upper chassis to the forward body part of thelower chassis (not shown in FIG. 5), and then extends toward therearward body part of the lower chassis. The slider 116 may comprise anencased motor that interacts with the continuous guide rod 166 along itsentire length via gears or friction wheels.

FIG. 5 depicts the path of travel of the face-sheet scanner 112′ as itmoves around the airfoil-shaped body from an initial position 202 at thebottom of the airfoil trailing edge to a final position 216 at the topof the airfoil trailing edge. The face-sheet scanner 112′ can be indexedin a conventional manner, taking measurements (e.g., ultrasonic scanningin a scan plane) at the initial position and each incremental positionthereafter until the final position is reached. The initial position 202and a multiplicity of intermediate positions 204, 206, 208, 210, 212,and 214 are shown in phantom in FIG. 5.

The position of slider 116 relative to the continuous guide rod 166 canbe measured by a second encoder incorporated in the motor that drivesslider travel along the guide rod. The relationship of slider position(relative to the guide rod) to scanner position (relative to theairfoil) can be determined empirically and used by the control computerto determine the scanner position as a function of the pulses from thesecond encoder, which encoder pulses are used by a control computer andby the ultrasonic pulser/receiver devices to determine the chordwisecoordinates of the acquired scan data. Alternatively, an encoder wheelcould be mounted to the scanner in a manner such that it rolls along theairfoil surface as the scanner is moved in a chordwise direction.

FIG. 6 shows some components of a blade crawler in accordance with afurther embodiment that is capable of performing nondestructiveinspection concurrently on the top and bottom surfaces and along theleading edge of the airfoil-shaped body. A pair of NDI scanner elements112, 112′ are respectively mounted to the distal ends of respective arms114, 114′, the proximal ends of which are coupled to respective sliders(not shown in FIG. 6) which travel along respective upper and lowerguide rods (not shown in FIG. 6) to enable simultaneous inspection ofthe upper and lower surfaces of the airfoil-shaped body 170. Thisembodiment is similar to the embodiment shown in FIG. 4 in that it hasupper and lower chasses which mirror each other, but instead of a commonguide rod that passes around the airfoil leading edge, there are twoseparate guide rods.

FIG. 7 shows the leading edge scanning assembly 180 depicted in FIG. 3,but on a magnified scale. This same leading edge scanning assembly canbe incorporated in the embodiment shown in FIG. 6. Referring to FIG. 7,the leading edge scanning assembly 180 comprises a leading edge scannerarray 181 carried by leading edge scanner frame 182 and positioned atthe leading edge of the airfoil-shaped body 170. The leading edgescanner frame 182 can take the form of an expandable bladder, a foammember, or an elastomeric member that causes the sensors to conform tothe leading edge of the airfoil-shaped body 170. Alternatively, theleading edge scanner frame 182 can include a plurality of springelements disposed between the inner surface of leading edge scannerframe 182 and adjacent surfaces of the leading edge scanner array 181.Other arrangements may also be used, such as a series of pivots orhinges, to orient the elements of the leading edge sensor array 181 tobe normal to confronting surface areas of the leading edge. As shown bythe double-headed arrow in FIG. 7, the crawler and the leading edgescanning assembly 180 supported thereon can be moved in a spanwisedirection so that the entire leading edge of the airfoil-shaped body 170can be scanned.

Data developed by the sensing elements 112 or 112′, as well as by theleading edge sensor array and the positional encoding mechanisms, arefed as analog or digital signals to a central computer (item 50 in FIG.9). The resulting output of the central computer can then be fed to adisplay device, such as a computer-driven display, thereby permitting anoperator to view results being obtained. This visual information givesan operator the opportunity to make appropriate adjustments to thescanner apparatus to ensure the desired scanning information isobtained.

The blade crawler described above can also be adapted for use in theautomation of various maintenance functions, including but not limitedto nondestructive inspection, drilling, grinding, fastening, appliquéapplication, scarfing, ply mapping, depainting, cleaning and painting.There are a number of types of blade components on aircraft that willbenefit from maintenance automation, including helicopter blades,propeller blades, flaps, ailerons, trim tabs, slats, stabilators andstabilizers. These operations enable the blade crawler to reducemaintenance time, reduce maintenance labor and reduce human error—allthrough automation of these normally manual processes.

FIG. 8 shows a rotary scarfer 220 supported by an adjustable chassis(comprising components 102, 104 and 150 as previously described) of ablade crawler. The rotary scarfer 220 is pivotably mounted to the distalend of arm 114, the proximal end of which is pivotably mounted to slider116 as previously described. Alternatively, the rotary scarfer 220 canbe mechanically oriented to achieve specific angularities using avariety of powered mechanisms for changing an orientation, such assolenoids, pneumatic actuators or radial motion transducers. The slider116 slides along a guide rod 118 which is integrally formed with amounting plate 172 that is fastened to the forward body part 102 by aplurality of fasteners 222.

While FIG. 8 shows an embodiment in which the end effector is a rotaryscarfer, it should be appreciated that other types of end effectors canattached to the distal end of arm 114. The rotary scarfer 220 may bepneumatically driven via a hose (not shown in FIG. 8) supplyingpressurized air from the operations center. The spanwise position of theblade crawler 100, the chordwise position of the rotary scarfer, and theoperation of the rotary scarfer (or other end effector) can becontrolled by the operations central computer in accordance with apre-programmed maintenance operation. It is also possible for the systemoperator to manually control functions by means of a joystick or numericcommands typed on a keyboard.

For many blade components made of laminated composite material, scarfingto eradicate skin damage is a common maintenance function. The automatedscarfing involves the removal of material (i.e., auguring) by means ofmilling using a high-speed rotary bit or mechanical sanding using anabrasive pad. Auguring is often performed in order to prepare acomponent surface for a hot bond repair. For example, plies of compositematerial could be removed in a damaged area to form a cavity suitablefor receiving a stack of plies of composite material designed to form arepair patch when cured in place. The use of an automated blade crawlercarrying a rotary scarfer would relieve mechanics of the tedious job oflocating scarf areas and precisely sanding or milling to remove damagedplies of composite material. Alternatively, a grinding tool could besubstituted for the rotary scarfer for removing bonded or boltedcomponents.

For many blade components, ply mapping as a prelude to the applicationof a repair patch is a common maintenance function. A ply mapper couldbe substituted for the rotary scarfer 220 seen in FIG. 8 and couldcomprise a digital photographic device or a touch probe device to definethe shape of the cavity formed during the scarfing operation. The goalis to acquire a three-dimensional measurement of the cavity, includingmeasurements indicating the shape of the cavity and lateral dimensionsof the cavity at various depths. Based on this information, plies havingthe appropriate shape and lateral dimensions can be cut and stacked inthe cavity for creating a repair patch. Often accomplished toautomatically define the contour of each repair ply, an automated plymapper blade crawler would relieve mechanics of the tedious job ofmanually mapping the plies for a repair patch.

For many blade components, drilling is a common maintenance function.Optionally the blade crawler disclosed herein may be equipped with anautomated driller to create holes for fasteners. Such a blade crawlerwould relieve mechanics of the tedious job of locating holes, drillingto exact specifications, countersinking and deburring.

For many blade components, depainting is a common maintenance function.Optionally the blade crawler disclosed herein may be equipped with anautomated depainter. Automated depainting using the blade crawlerdisclosed herein could include mechanical sanding, automated chemicalapplication, rinse and collection, or automated media blast with debriscollection. Often accomplished to remove old paint from the componentsurface, an automated depainter blade crawler would relieve mechanics ofthe tedious job of precision hand sanding, media blasting, vacuumingaway liquid, dust and debris, or chemical treatment.

For many blade components, cleaning is a common maintenance function.Optionally the blade crawler disclosed herein may be equipped with anautomated cleaner. An automated blade crawler for cleaning would includea set of end effectors, including a cleaning solution squirter, anautomated wiper/scrubber/buffer, and a rinse solution squirter alongwith a vacuum collection device. Often accomplished to remove dirt anddebris from the component surface, an automated cleaning blade crawlerwould relieve mechanics of the tedious job cleaning large areas on theblade component.

For many blade components, painting is a common maintenance function.Optionally the blade crawler disclosed herein may be equipped with anautomated painter. The automated painting end effector devices couldinclude sprayers, rollers and applicators along with a vacuum collectionsystem. Often accomplished to recover the component surface, anautomated painter blade crawler would relieve mechanics of the tediousjob of precision hand painting of the blade component.

FIG. 9 is a block diagram showing communications between a controlcomputer 50 and various components of an end effector-carrying bladecrawler in accordance with one embodiment. In this instance, the controlcomputer 50 is connected to the blade crawler by an electrical cable(not shown). (Alternatively, the control computer and the blade crawlercould communicate wirelessly.) The control computer 50 may be programmedto control a cable management system (not shown). For example, motioncontrol application software running on computer 50 can control a cablemotor 48 of the cable management system. When the blade crawler isoperated, one or more cables need to accompany the crawler down thelength of the airfoil-shaped body, e.g., a helicopter blade. The motioncontrol software running on computer 50 synchronizes the movement of thecables with the movement of the blade crawler, extending or retractingthe cables as appropriate. The computer system is programmed to controlthe cable motor 48 in dependence on crawler spanwise-positioninformation derived from pulses generated by a crawler position encoder146 (e.g., coupled to encoder wheel 144 seen in FIG. 1). In addition,the control computer 50 controls the crawler scan drive motor 132 independence on the pulses from crawler position encoder 146.

When the crawler reaches a target spanwise position, the controlcomputer 50 shuts off the crawler scan drive motor 132 and then startsan end effector scan drive motor 52, e.g., a drive motor which movesslider 116 along the guide rod 118 seen in FIG. 1. The computer systemis programmed to control the end effector scan drive motor 52 independence on the end effector chordwise-position information derivedfrom pulses generated by an end effector position encoder 148.

In cases where the end effector is a rotary tool (such as a scarfer,drill, deburrer or reamer), when the rotary tool reaches a targetchordwise position, the control computer 50 shuts off the end effectorscan drive motor 52 and then starts an end effector motor 54, e.g., adrive motor which drives rotation of the rotary tool. It should beappreciated that in cases where the end effector is emitting oringesting a liquid or particles, the control computer will activate apump. In cases where the end effector's elevational position isadjustable by operation of an actuator, such actuator may also becontrolled by the computer.

Alternatively, in cases where a motion-producing device (such as amotor, solenoid, piston, etc.) is actuated to cause the crawler to gripthe airfoil-shaped body, actuation of that motion-producing device mayalso be controlled by the control computer 50.

An automated blade crawler carrying any one of a multiplicity of endeffectors, as disclosed above, may also have any one of a multiplicityof configurations that enable movement, positional tracking and tractionalong an airfoil component. Included in these configurations aremultiple options for wheels and/or rollers, grip mechanism, positionaltracking mechanisms, and braking devices. These configurations operatein conjunction to enable the functions that ensure that the crawlerdeploys effectively. As a whole, the blade crawler reduces maintenancetime, lab or hours and human errors when NDI or maintenance areperformed on blade components.

As part of the crawling automated scanner apparatus, the movement andalignment mechanisms perform multiple functions that enable the entireapparatus to operate in the NDI or maintenance modes: (1) causing theapparatus to move in a spanwise direction along the blade; (2) trackingthe spanwise position of the apparatus relative to the blade; and (3)ensuring that the apparatus does not slip along the blade. Morespecifically, the chassis of the crawler should be capable of locomotionalong the blade component; the spanwise position of the chassis alongthe blade component should be tracked to enable the operations of theapparatus to be properly conducted; and during operations where side andnormal forces are acting on the end effector, the apparatus shouldmaintain a constant position along the spanwise direction of the bladecomponent

These functions are enabled by components of the movement and alignmentmechanisms which are detailed in the following sections respectivelyentitled: (A) Wheel Configurations; (B) Chordwise Grip MechanismConfigurations; (C) Positional Tracking Mechanisms; and (D) BrakeConfigurations.

Wheel Configurations

In the embodiment shown in FIG. 8, the blade crawler grips theairfoil-shaped body by means of a drive track 134 in contact with theleading edge and an encoder wheel 144 in contact with the trailing edge.Many other roller/wheel configurations can be used in place of a drivetrack at the leading edge to move the crawler. For example, either agrooved or a flat drive roller, with or without alignment rollers orwheels, can be used to apply the driving force at or near the leadingedge for causing spanwise displacement of the crawler. The wheelsconvert kinetic energy from a rotating shaft into work that moves thecrawler along airfoil-shaped body.

FIG. 10 shows a grooved drive roller 60 and a pair of parallel-axisalignment wheels 64 and 66 in contact with a leading edge of anairfoil-shaped body 170 in accordance with one embodiment. The driveroller 60 may have a curved groove 62 that matches or nearly matches thecurved profile of the leading edge, or the groove may be V-shaped. Thedrive roller 60 is preferably made of a high-traction material thatensures a positive grip when the drive roller applies contact pressureon the leading edge of the airfoil-shaped body 170. Alignment wheels 64,66 may be arranged to have a common axis of rotation B that is parallelto, but displaced from the axis of rotation A of the drive roller 60,i.e., multiple parallel axles with independent housings. Alignment isensured when the grooved drive roller 60 and alignment wheels 64, 66trap the contour of the leading edge. Alternatively, the drive roller 60and alignment wheels 64, 66 could have a common axis of rotation or thealignment wheels 64, 66 could have non-parallel axes of rotation (seealignment wheel axes of rotation C and D in FIG. 11).

FIG. 11 shows a flat (i.e., circular cylindrical shape) drive roller 68and a pair of off-axis alignment wheels 64 and 66 in contact with aleading edge of an airfoil-shaped body 170 in accordance with anotherembodiment. The drive roller 68 is preferably made of a high-tractionmaterial that ensures a positive grip when the drive roller appliescontact pressure. Alignment is ensured when the flat drive roller 68 andalignment wheels 64, 66 trap the contour of the leading edge.Alternatively, alignment wheels 64, 66 may be arranged to have a commonaxis of rotation that is parallel to, but displaced from the axis ofrotation A of the flat drive roller 68 (similar to the arrangement seenin FIG. 10), or the flat drive roller 68 and alignment wheels 64, 66could have a common axis of rotation.

FIG. 12 shows a further alternative configuration in which a flat driveroller 68 is arranged to contact an upper surface area that is part ofor located near the leading edge of the airfoil-shaped body 170 and asingle off-axis alignment wheel 66 is arranged to contact a lowersurface area that is part of or located near the leading edge of theairfoil-shaped body 170. Alignment is ensured when the flat drive roller68 and alignment wheel 66 trap the contour of the leading edge.Alternatively, the positions of flat drive roller 68 and alignment wheel66 could be switched.

Flat or grooved alignment rollers (no drive function) could be used inplace of alignment wheels in any one of the configurations disclosedherein. Also tracked alignment wheels with no drive function could beemployed.

FIG. 13 shows a pair of off-axis alignment wheels 64, 66 in contact witha leading edge of an airfoil-shaped body 170, the alignment wheels beingrotatably mounted on a flexible axle 70 in accordance with a furtherembodiment. The flexible axle may be made of metal or metal alloy,polymeric material, spring material, or other suitable material. Theflexible axle support assembly comprises a rigid upper arm 72 having oneend pivotably coupled to one end of the flexible axle 70 by a pivotjoint 78 and another end threadably coupled to one end of an expansionsleeve 76; and a rigid lower arm 74 having one end pivotably coupled tothe other end of flexible axle 70 by a pivot joint 80 and another endthreadably coupled to the other end of expansion sleeve 76. The threadscoupling the expansion sleeve 76 to arms 72 and 74 are configured sothat rotation of sleeve 76 in one direction causes the opposing threadedends of arms 72 and 74 to move further apart (also causing pivot joints78 and 80 to move further apart), whereas rotation of sleeve 76 in theopposite direction causes the opposing threaded ends of arms 72 and 74to move closer to each other (also causing pivot joints 78 and 80 tomove closer together). The radius of curvature of the flexible axle 70decreases as pivot joints 78 and 80 move toward each other, andincreases as pivot joints 78 and 80 move away from each other, therebyallowing the positions of alignment wheels 64 and 66 to be adjusted tobetter fit the contour of the leading edge of airfoil-shaped body 170.The flexible axle 70 also conforms under pressure to the shape of theleading edge. The alignment mechanism shown in FIG. 13 may be used inconjunction with a drive track or one or more drive rollers of a typepreviously described.

Optionally, position encoders may be provided which output pulsesrepresenting the rotation of encoder wheels which respectively engagethe trailing and leading edges of the airfoil-shaped body. These encoderpulses are transmitted to the control computer, which is programmed tomonitor the respective displacements of those encoder wheels along bothedges and then compensate if the crawler begins to rotate duringspanwise translation.

Chordwise Grip Mechanism Configurations

Any one of a multiplicity of chordwise grip mechanisms can be employedto enable the movement and alignment mechanism functions. Each chordwisegrip mechanism causes the wheels to act on the blade leading andtrailing edges by imparting a normal force to the wheels. One or morechordwise grip mechanisms may be employed on an apparatus to provideoptimum functionality.

One suitable chordwise grip mechanism configuration is the lineartelescoping sleeve mechanism previously described with reference toFIG. 1. A sufficient gripping force is generated when the telescopingsleeve (i.e., the rearward body part 104) retracts, causing the driveroller and alignment wheels to engage the leading edge and the encoderwheel (which also functions as an alignment wheel) to engage thetrailing edge. Any one of a multiplicity of known linear motion devicescan be employed to cause the rearward body part 104 to retract relativeto the intercostal element 150, including the following: a solenoid, apiston, a rack and pinion assembly, a spring, or other translationmechanism.

Alternative chordwise grip mechanism configurations are shown in FIGS.14-18.

FIG. 14 is a diagram showing an isometric view of portions of a bladecrawler in accordance with an alternative embodiment in which thecrawler carries a rotary scarfer 220 and the adjustable chassiscomprises a chordwise grip mechanism having a pincer configuration.Instead of using a linear telescoping sleeve mechanism as shown in FIG.3, the chordwise grip mechanism depicted in FIG. 14 comprises a frame224 and a pincer arm 226, one end of which is pivotably coupled to frame224 by a pivot joint 228 and the other end of which supports rod 142that carries the encoder wheel 144. Mounting plate 172, which isintegrally formed with the guide rod 118, is fastened to the frame 224.Frame 224 also supports the drive motor 132 and follower wheel 124. Asufficient gripping force is generated when the pincer arm 226 isrotated into a position in contact with the trailing edge of theairfoil-shaped body 170, sufficient force being applied to cause thedrive roller 122 and follower wheel 124 to engage the leading edge whilethe encoder wheel 144 engages the trailing edge. Any one of amultiplicity of known radial motion devices (not shown in FIG. 14) canbe employed to apply the torque on pincer arm 226, such as a motor, ascrew drive lever, a rack and pinion assembly, or a torsion spring.

In accordance with an alternative chordwise grip mechanism, one end of asecond pincer arm could be pivotably mounted on the other end of frame224, while the other end of the second pincer arm supports the axle offollower wheel 124. In this embodiments having a pincers configuration,the first pincer arm (item 226 in FIG. 14) would be rotated into contactwith the trailing edge, while the second pincer arm would be rotatedinto contact with the leading edge to create the desired chordwisegripping force.

FIG. 15 shows portions of a blade crawler in accordance with analternative embodiment in which the crawler carries a rotary scarfer 220and the adjustable chassis comprises a chordwise grip mechanism having ascissors configuration. This chordwise grip mechanism comprises a frame230 and a pair of scissor arms 232 and 234 which are pivotably coupledat their midpoints by a pivot joint 236. One end of scissor arm 232 ispivotably coupled to frame 230 by a pivot joint 238 and the other end ofscissor arm 232 supports drive motor 132. One end of scissor arm 234carries a pin 240 which is slidably disposed inside a linear slot (orgroove) 242 formed in frame 230 and the other end of scissor arm 234supports follower wheel 124. In one embodiment, slot 242 is disposed inthe spanwise direction. As pin 240 slides back and forth inside slot242, the scissors mechanism alternately opens and closes. For example,when pin 240 moves away from pivot joint 238, the scissors mechanismcloses, causing drive roller 122 and follower wheel 124 to be moved intocontact with and pressed against the leading edge of the airfoil-shapedbody 170, while the encoder wheel is being pressed against the trailingedge, thereby producing the gripping force. Any one of a multiplicity ofknown translation devices (not shown in FIG. 15) can be employed to movepin 240 along the length of slot 242, such as a motor, a piston, asolenoid, a screw drive lever, a rack and pinion assembly, or a spring.

In accordance with another embodiment shown in FIG. 16, the chordwisegrip mechanism comprises four links 250 a-250 d which are pivotablycoupled in a clam-shell configuration to form a chassis 250. Respectivefirst ends of links 250 a and 250 d are pivotably coupled by a pivotjoint 252, while respective first ends of links 250 b and 250 c arepivotably coupled by a pivot joint 254. At the same time, respectivesecond ends of links 250 a and 250 b, as well as an upper rollermounting arm 256 a disposed therebetween, are all pivotably mounted to afirst axle 258, while respective second ends of links 250 c and 250 d,as well as a lower roller mounting arm 256 b disposed therebetween, areall pivotably mounted to a second axle 260. In accordance with oneembodiment, a drive roller 262 is rotatably mounted on an axle 264projecting from a distal end of the upper roller mounting arm 256 a,while a flat roller 266 (not driven) is rotatably mounted on an axle 268projecting from a distal end of the lower roller mounting arm 256 b. Theclam-shell chassis 250 can be configured (by rotation of links 250 a-d)so that when the upper and lower roller mounting arms 256 a and 256 bare moved toward each other, they press drive roller 262 against theupper surface and alignment roller 266 against the lower surface of theairfoil-shaped body 170 with sufficient normal force that the resultingfriction force enables the drive roller 262 to move the crawler in aspanwise direction without slippage. At the same time, a pair ofalignment wheels 270 a and 270 b supported by link 250 b and an encoderwheel 144 supported by arm 272 projecting from link 250 a maintain thealignment of the crawler on the airfoil-shaped body during spanwisetravel. Any one of a multiplicity of known motion devices (not shown inFIG. 16) can be employed to pinch the upper and lower halves of thechassis 250 together, such as motors, pistons, solenoids, screw drivelevers, or springs.

FIG. 17 is a diagram showing an isometric view of portions of a bladecrawler in accordance with a variation of the embodiment depicted inFIG. 16. In this variation, the fourth link (item 250 d in FIG. 16) ofthe adjustable chassis has been eliminated, and pivoting of the thirdlink 250 c relative to the second link 250 b in either directioninvolves meshed gears or a controlled solenoid (not shown), which canpositively urge the third link 250 c in a direction that causesalignment roller 266 to press against the bottom surface of theairfoil-shaped body 170 while drive roller 262 is being urged againstthe top surface.

FIG. 18 shows portions of a blade crawler in accordance with yet anotherembodiment in which the crawler carries a rotary scarfer 220 and theadjustable chassis 280 comprises four links 280 a-280 d which arepivotably coupled in a press configuration. Respective first ends oflinks 280 a and 280 d are pivotably coupled by a pivot joint 282;respective first ends of links 280 b and 280 c are pivotably coupled bya pivot joint 286; respective second ends of links 280 a and 280 b arepivotably coupled by a pivot joint 284; and respective second ends oflinks 280 c and 280 d are pivotably coupled by a pivot joint 288. Thepress chassis 280 can be configured (by rotation of links 280 a-d) sothat when the pivot joints 284 and 288 are moved away from each other,the drive roller 122 and follower wheel 124 engage the leading edgewhile the encoder wheel 144 engages the trailing edge of theairfoil-shaped body 170. By continuing to apply a force urging the pivotjoints 284 and 288 apart, the drive roller 122, follower wheel 124 andencoder wheel 144 can produce the gripping force for proper automatedoperation of the blade crawler. Again, any one of a multiplicity ofknown motion devices (not shown in FIG. 18) can be employed to pressdrive roller 122 and follower wheel 124 against the leading edge andencoder wheel 144 against the trailing edge, such as motors, pistons,solenoids, screw drive levers, or springs.

Position Tracking Mechanisms

In accordance with the embodiments described above, the control computeris provided with information concerning the spanwise position of thecrawler. This functionality can be provided by any one of a multiplicityof known positional tracking mechanisms.

In accordance with some embodiments, an optical tracking system can beused to determine the spanwise position of the crawler. For example,U.S. Pat. No. 7,643,893 discloses a motion capture system whereinmultiple motion capture cameras are set up around the object to bescanned to create a three-dimensional capture volume that capturesmotion for all six degrees-of-freedom of the object being tracked. Theobject to be tracked has a respective group of passive retro-reflectivemarkers (at least three) attached thereto, the markers of each groupbeing arranged in a respective unique pattern. The markers of each groupare arranged in known patterns, and the information for defining thepatterns is stored in a motion capture processor. Each group of markersmay comprise a plurality of small spheres (e.g., about ¼ inch indiameter) attached to a rigid platform. Each motion capture camera canbe a video camera of the type comprising a ring of LEDs surrounding acamera lens. In conjunction with such cameras, each retro-reflectivemarker may comprise a hemispherical or ball-shaped body coated withreflective paint that that reflects impinging light from the LEDs ofeach camera back toward the associated lens of the respective camera ina well-known manner. The motion capture system utilizes data capturedfrom image sensors inside the cameras to triangulate thethree-dimensional position of the target object between multiple camerasconfigured to provide overlapping projections.

Alternatively, the optical tracking mechanism may comprise a localpositioning system of the type disclosed in U.S. Pat. No. 8,044,991.

In the alternative (as previously described with reference to FIG. 1),the positional tracking of the crawler's spanwise position may beprovided by a rotary encoder (not shown in FIG. 1) coupled to an encoderwheel (item 144 in FIG. 1). The rotary encoder sends encoder pulses tothe control computer which allow the latter to determine the spanwisecoordinate of the crawler. The rotary encoder can be coupled to afollower encoder wheel or to a drive roller or drive wheel. In thealternative, a separate encoder wheel could be pivotably mounted to thecrawler chassis at the end of a spring-loaded arm which urges theencoder wheel into contact with the upper surface of the airfoil-shapedbody.

In accordance with other embodiments, the crawler positional trackingmechanism may comprise a light-emitting diode and a photodiode mountedto the crawler chassis in a relationship similar to what is incorporatedin an optical computer mouse. This positional tracker uses an imagesensor to image naturally occurring texture in the airfoil surface.

Images of the surface are captured in continuous succession and comparedwith each other, using a process known as digital image correlation, todetermine how far the crawler has moved.

In accordance with a further alternative, a capacitive linear encodercan be used to track the spanwise position of the crawler. Respectiveprinted circuit boards of a capacitive linear encoder can be mounted onthe crawler chassis and on a confronting surface of the airfoil-shapedbody (the latter being removable) so that the printed circuit boards arecapacitively coupled. As the crawler moves, the capacitance changes in alinear fashion and in a repeating manner. Alternatively, inductive ormagnetic linear encoders can be used.

Brake System Configurations

Optionally, the blade crawlers disclosed herein may be provided with abraking system which engages the airfoil-shaped body with sufficientforce to prevent movement of the crawler during the performance of NDIor a maintenance operation. This functionality can be provided by anyone of a multiplicity of known brake mechanisms.

In accordance with one embodiment shown in FIG. 19, the brakingmechanism comprises a friction pad pressure foot 290 mounted on the endof a vertically displaceable shaft 292. The shaft 292, in turn, isoperatively coupled to an actuator 294 mounted to the intercostalelement 150 of a linear telescoping sleeve chordwise grip mechanism.Such a brake mechanism can be readily mounted to the various crawlerchasses shown in FIGS. 14 through 18. The actuator 294 may take the formof any translation or radial motion device such as a motor, solenoid,piston, rocker mechanism, etc.

Alternatively, a pressure foot brake mechanism could be mounted to anend effector 220 as shown in FIG. 20. In this case, the friction padpressure foot 290 is mounted on the end of a pivotable arm 296 connectedto a radial motion device 298. Any one of a multiplicity of known radialmotion devices can be employed to apply the torque on arm 296, such as amotor, a screw drive lever, a rack and pinion assembly, or a torsionspring.

In place of the friction pad pressure foot employed in the embodimentsdepicted in FIGS. 19 and 20, the brake mechanism may comprise a suctioncup.

In accordance with alternative braking mechanisms, a brake may beincorporated in the motor which drives spanwise movement of the crawler,or a pressure pad or disc brake could be operated to engage a driveroller or alignment wheel.

Adjustable Blade Tip Stabilizing Apparatus

To facilitate the mounting and removal of the automated blade crawlerdisclosed herein and prevent damage to the rotorcraft blade due to theweight of the crawler, an adjustable blade tip stabilizing apparatus isprovided for supporting the tip of a rotorcraft blade during inspectionor maintenance. This feature enables the crawler to function on smalleror less stiff rotorcraft blades without overloading them. It also allowsautomated crawlers of various weights to be used on lighter, moreflexible blades without harming the blades.

One embodiment of an adjustable blade tip stabilizing apparatus 10 isshown in FIGS. 21A and 21B. This apparatus is designed to support thetip of a rotorcraft blade 174, which extends radially from a root end176, when an automated blade crawler 100 is placed on the blade. Theautomated blade crawler 100 is connected to an operations center (notshown) by means of cables 120 (only partly shown). The cables 120 may,for example, comprise a cable for electrical power, electrical data, andelectrical control signals, and a hose supplying pressurized air orliquid.

In accordance with the embodiment shown in FIGS. 21A and 21B, theadjustable blade tip stabilizing apparatus 10 comprises a cable payoutroll assembly that is mounted on and extends upward from a personnelladder 16. The personnel ladder 16 is scaleable by the personnelassigned to the task of mounting or removing the blade crawler 100 fromthe blade 174.

The cable payout roll assembly comprises a free-rolling or motorizedcable payout roll set 12, 14, each roll having one end rotatably coupledto a frame 24 that may be rigidly connected to the personnel ladder 16.The cable payout roll set 12, 14 enables free scanning of the automatedblade crawler without dragging or binding of the cables.

The blade tip stabilizing apparatus further comprises a tip grip 20which is mounted on the upper part 18 a of a height adjustmentmechanism. The lower part 18 b of the height adjustment mechanism isfixedly attached to the personnel ladder 16. The upper part 18 b can bemoved upward or downward relative to the lower part 18 a, allowing theheight of the tip grip 20 to be adjusted as a function of the height ofthe blade tip. The tip grip 20 is designed to couple to the blade tipand provide support to prevent the latter from displacing downward underthe weight of the blade crawler 100. The height of the tip grip 20 maybe adjusted so that the rotorcraft blade 174 is disposed in a horizontalplane.

In accordance with one embodiment, the upper and lower parts 18 a, 18 bof the height adjustment mechanism may comprise mutually telescopingparts, one slidable within the other when the mechanism is manuallyunlocked. After the height has been adjusted, the upper part can bemanually locked in place so that it cannot be moved relative to thelower part.

In accordance with an alternative embodiment, the upper and lower parts18 a, 18 b of height adjustment mechanism may comprise mutuallyinterengageable parts that are driven to displace relative to each otherby a system in which at least one gear is driven to rotate by manualoperation of a crank or by activation of a motor.

A laser leveler 22 (mounted to the upper portion 18 a of the heightadjustment mechanism) can be utilized to determine when the adjustedheight of the tip grip 20 (now coupled to the blade tip) causes blade174 to be in a horizontal position. A laser leveler is a device that canbe spun to illuminate a horizontal plane with a rotating laser beam 126(see FIG. 21A). A sensor can be placed on the root end 176 of therotorcraft blade 174, which sensor can detect the laser beam 126 andgive a signal when the sensor is in line with the beam, i.e., when theblade is horizontal.

The process steps for using the apparatus depicted in FIG. 21A are asfollows:

-   -   (1) The maintainer sets up the adjustable blade tip stabilizing        apparatus 10 at the tip end of an installed rotorcraft blade        174.    -   (2) The maintainer climbs the adjustable blade tip stabilizing        apparatus 10.    -   (3) The stabilizer tip grip 20 is coupled to the tip of        rotorcraft blade 174.    -   (4) The laser leveler 22 is turned on and the height of the tip        grip/blade tip is adjusted using the laser line indication as a        guide.    -   (5) The maintainer picks up and carries the automated blade        crawler 100 up the steps of the personnel ladder 16.    -   (6) The maintainer couples the crawler 100 to the rotorcraft        blade 174 at a position near the tip of the blade.    -   (7) The cable (or cables) 120 is inserted between the cable        payout rollers 12, 14.    -   (8) A test scan is performed to verify the scanning movement and        scanner performance for NDI or other maintenance operations.    -   (9) The maintainer starts the crawler 100 and dismounts from the        personnel ladder 16.    -   (10) The automated blade crawler 100 performs its programmed        function (NDI, repair, drilling, etc.) and then returns to a        position near the rotorcraft blade tip.    -   (11) The maintainer climbs up the personnel ladder 16 and        removes the crawler 100 from the blade 174.    -   (12) The maintainer then uncouples the tip grip 20 from the        blade tip.    -   (13) The maintainer climbs off of the personnel ladder 16.    -   (14) The maintainer repeats the above steps as needed for the        remaining rotorcraft blades to be maintained.    -   (15) The maintainer collapses the rotorcraft blade stabilizer        for storage.

The blade tip stabilizing apparatus shown in FIGS. 21A and 21B solvesthe following problems: (a) The maintainer needs to get the crawler onand off the rotorcraft blade before and after its use. (b) Smaller ormore flexible rotorcraft blades may not be able to handle the fullweight of the crawler without support and/or stabilization. (c) Movementof the crawler along the rotorcraft blade may be inhibited by the powerand communication cabling that goes between the crawler and theoperations center.

While automated blade crawlers have been described with reference toparticular embodiments, it will be understood by those skilled in theart that various changes may be made and equivalents may be substitutedfor elements thereof without departing from the scope of the teachingsherein. In addition, many modifications may be made to adapt aparticular situation to the teachings herein without departing from theessential scope thereof. Therefore it is intended that the claims setforth hereinafter not be limited to the disclosed embodiments.

As used in the claims, the term “computer system” should be construedbroadly to encompass a system having at least one computer or processor,and which may have two or more interconnected computers or processors.

1. A method for deploying an automated apparatus on an installed rotorcraft blade having a tip, comprising: (a) mounting a height adjustmentmechanism comprising a grip to a ladder, wherein the height adjustmentmechanism comprises a lower part attached to the ladder and an upperpart movably coupled to the lower part; (b) placing the ladder on theground at a position so that the grip grips the tip of the rotorcraftblade; (c) adjusting a height of the upper part of the height adjustmentmechanism relative to the ladder until the rotorcraft blade is disposedin a horizontal plane; (d) placing the automated apparatus on therotorcraft blade such that a weight of the automated apparatus issupported by the rotorcraft blade while the tip of the rotorcraft bladeis being supported by the grip; and (e) moving the automated apparatusin a spanwise direction along the rotorcraft blade while the tip of therotorcraft blade is being supported.
 2. The method as recited in claim1, wherein placing the automated apparatus on the rotorcraft bladecomprises placing a first rolling element in rolling contact with aleading edge of the rotorcraft blade and placing a second rollingelement in rolling contact with a trailing edge of the rotorcraft blade.3. The method as recited in claim 1, further comprising: ceasingmovement of the automated apparatus in the spanwise direction; andmoving an end effector of the automated apparatus in a chordwisedirection relative to the rotorcraft blade while the automated apparatusis not moving in the spanwise direction.
 4. The method as recited inclaim 3, further comprising activating the automated apparatus toperform a programmed function during movement of the end effector in thechordwise direction.
 5. The method as recited in claim 1, furthercomprising: mounted a pair of rollers to the ladder; and placing a cablehaving one end connected to the automated apparatus between the pair ofrollers.
 6. The method as recited in claim 1, further comprising:attaching a sensor to a root end of the rotorcraft blade; attaching alaser to the upper part of the height adjusting mechanism; transmittinga laser beam from the laser as the upper part of the height adjustingmechanism is moving during adjusting; and determining when the sensor isaligned with the laser beam.
 7. The method as recited in claim 1,wherein step (d) comprises placing a first rolling element in rollingcontact with a leading edge of the rotorcraft blade and placing a secondrolling element in rolling contact with a trailing edge of therotorcraft blade.
 8. The method as recited in claim 1, wherein step (d)is performed by a person standing on the ladder.
 9. An apparatuscomprising a ladder, a frame member attached to the ladder, a heightadjustment mechanism comprising a lower part attached to the ladder andan upper part which is coupled to the lower part of the heightadjustment mechanism, a pair of cable pay-out rollers rotatably coupledto the frame member, and a grip attached to the upper part of the heightadjustment mechanism, wherein the grip is configured to engage andstabilize a tip of a rotorcraft blade, and the height of the upper partof the height adjustment mechanism is adjustable by movement relative tothe lower part.
 10. The apparatus as recited in claim 9, wherein theupper and lower parts of the height adjustment mechanism comprisemutually telescoping parts, one slidable within the other when theheight adjustment mechanism is manually unlocked.
 11. The apparatus asrecited in claim 9, further comprising at least one gear, wherein theupper and lower parts of the height adjustment mechanism comprisemutually interengageable parts that are driven to displace relative toeach other when the at least one gear is driven to rotate.
 12. Theapparatus as recited in claim 9, further comprising a laser levelerattached to the upper part of the height adjustment mechanism.
 13. Theapparatus as recited in claim 9, wherein each of the pair of cablepay-out rollers have one end rotatably coupled to the frame.
 14. Asystem comprising: an airfoil-shaped body having leading and trailingedges which extend from a root to a tip; a tip support assemblycomprising a frame, a height adjustment mechanism comprising a lowerpart attached to the frame and an upper part which is coupled to thelower part of the height adjustment mechanism, first and second cablepay-out rollers rotatably coupled to the frame, and a grip attached tothe upper part of the height adjustment mechanism and coupled to the tipof the airfoil-shaped body, wherein the height of the upper part of theheight adjustment mechanism is adjustable by movement relative to thelower part; an automated blade crawler mounted to the airfoil-shapedbody, the automated blade crawler comprising an end effector, firstmeans for moving the blade crawler in a spanwise direction along theairfoil-shaped body, and second means for moving the end effector in achordwise direction; and a cable having one end connected to theautomated blade crawler and having another portion disposed between thefirst and second cable pay-out rollers.
 15. The system as recited inclaim 14, wherein the end effector comprises one of the following: anondestructive inspection sensor, a rotary tool, a ply mapper, asquirter, a sprayer, a roller that carries liquid and a suction device.16. The system as recited in claim 14, further comprising a controlcomputer connected to another end of the cable, the control computerbeing programmed to control the first and second means for moving. 17.The system as recited in claim 14, wherein the upper and lower parts ofthe height adjustment mechanism comprise mutually telescoping parts, oneslidable within the other when the height adjustment mechanism ismanually unlocked.
 18. The system as recited in claim 14, furthercomprising at least one gear, wherein the upper and lower parts of theheight adjustment mechanism comprise mutually interengageable parts thatare driven to displace relative to each other when the at least one gearis driven to rotate.
 19. The system as recited in claim 14, furthercomprising: a sensor attached to a root end of the rotorcraft blade; anda laser leveler attached to the upper part of the height adjustmentmechanism.
 20. The system as recited in claim 14, wherein each of thefirst and second cable pay-out rollers have one end rotatably coupled tothe frame.